Apparatus and method for assembly of rods and plates



@ct 30, 1956 F, 1 HUGHES 2,768,431

APPARATUS AND METHOD FOR ASSEMBLY 0R RODS AND PLATES FIG. 5`

FIG. 2.

INVENTOR. FRANCIS J. HUGHES Oct. 30, 1956 F. J. HUGHES 68,431

APPARATUS AND METHOD FOR ASSEMBLY OF RODS AND PLATES Filed May 14, 1953v s sheets-sheet 2 HAAN INVENTOR. FRANCIS J. HUGHES Oct. 30, 1956 F. J.HUGHES y 2368,43

APPARATUS AND METHOD FOR ASSEMBLY OF RODS AND PLATES Filed May 14, 19535 Sheets-Sheet E5 JNVENTOR.

FRANCIS J. HUGHES FIG. 4.

Oct. 30, 1956 F. J. HUGHES 2,768,431

APPARATUS AND METHOD FOR ASSEMBLY OF RODS AND PLATES Filed May 14, 149535 Sheets-Sheet 4 INVENToR. FRANCIS J. HUGHES Oct. 30, 1956 F. J. HUGHES2,768,431

APPARATUS AND METHOD PoR ASSEMBLY DP Pons AND PLATES JNVENToR. FRANCISJ. HUGHES United States Patent O APPARATUS AND METHOD FOR ASSEMBLY OFRODS ANI) PLATES Francis J. Hughes, Drexel Hill, Pa., assigner to Oxy-Catalyst, Inc., a corporation of Pennsylvania Application May 14',195l3, Serial N o. 354,985'

4 Claims. (Cl. 29-428) This invention is concerned with a method andapparatus to assist in the assembly of units comprised of a number ofrods supported between a pair of end plates 'which is provided withapertures to receive them. The

Vassembly of units of this type presents a diiicult problem,

particularly when the rods making up the unit are disposed in closelyspaced relation.

. It is an object of the invention to provide a relatively simplyconstructed and easily operated assembly jig to assist in the assemblyof such units.

It is a further object of the invention to provide a method of assemblywhich permits such units to be assembled with greatly increased rapidityand ease.

To facilitate understanding of the invention, reference is now made tothe accompanying drawings which illustrate a preferred embodiment of anassembly jig constructed in accordance with the principles of theinvention. In the drawings:

Fig. l is a perspective view, with parts broken away, of a typical lunitwhich may be quickly and easily assembled using the apparatus and methodof the invention;

Fig. 2 is a cross-sectional view through the center of one of the endplates making up the unit illustrated in Fig. l;

Fig. 3 is a front plan view of an assembly jig constructed in accordancewith the invention, shown containing a partially assembled unit of thetype illustrated in Fig. 1.

, Fig. 4 is a side elevation of the jig illustrated in Fig.

yand 5 with parts in section;

Fig. 7 is a top plan view of a portion of the assembly jig illustratedin the previous figures, shown in one operative position;

Fig. 8 is a view similar to Fig. 7, showing a portion of the assemblyjig in another operative position; and

Fig. 9 is a top plan View showing a different arrangement of one portionof the assembly jig adapted for the assembly of a unit of somewhatdifferent construction than that illustrated in Fig. 1.

Referring now to Fig. 1, the unit illustrated in this iigure consists ofa plurality of rod-like elements 1 which are supported between a pair ofend plates 2 provided with apertures 3 to receive them. In theparticular unit illustrated, the apertures 3 are sized slightly largerthan the rods 1 to permit the rods to be retained in these apertureswith a loose sliding lit. The end plates 2 are Supported by a sturdycenter post 4 which is cemented in sockets 5 provided in either endplate. To facilitate aS- sembly, the edges of the apertures 3 arebevelled as at 6 (see Fig. 2) permitting the rods 1 to register moreeasily 'with these apertures during assembly. In the 2,768,431 PatentedOct. 30, .1956

ice

particular unit shown, the rods 1 and the apertures 3 are tear drop incross-section as may be seen in Fig. 5.

The unit illustrated in Fig. l is described and claimed in copendingapplication Serial No. 159,191, led May 1, 1950, by Eugene J. Houdry forProcess and Apparatus for Contacting Operations now Patent No.2,730,434. This unit, particularly when composed of ceramic materialsuch as a high quality porcelain, is excellently adapted for carryingout reactions involving contact of gaseous reactants with a surface. Inparticular, such a unit in which the rods 1 are composed of a highquality porcelain may be provided with a thin film of an oxidationcatalyst, and employed in this form as a catalytic unit for carrying outcatalytic oxidation reactions in the fluid phase, the fluid reactantsflowing through the unit in Contact with the rodlike elements 1. Toprovide eilicient contact between the fluid reactants and the catalyticsurface, the rods 1 are closely spaced in staggered rows. This type ofarrangement is easily observed in Figs. 5, 7, and 8 where it may be seenthat the rods 1 are arranged in parallel rows, the rod-like elements ineach row being staggered with respect to the units in adjacent rows.

Such units are preferably smml in size, a typical unit having thedimensions of 3" X 3 X 6 and containing a total of 73 closely spacedrods in addition to the center post 4. Because of the close spacing andrelatively small dimensions of these rods, the assembly of such a unitpresents a rather difficult problem.

Although the invention will be illustrated with reference to theassembly of such unit, it is to be understood of course that theprinciples of the invention are equally applicable to the assembly ofmany other types of units of similar construction.

Referring now particularly to Figs. 3 and 4 which show respectively afront and side elevation of the assembly jig, it may be seen that thejig consists generally of a base 7 from which is supported an uprightframe which includes a pair of upright posts 8. As illustrated in thedrawing, the base 7 of the assembly jig is shown resting upon a vibratorunit generally designated by the reference numeral 9, the purpose ofwhich will be described in detail hereafter.

On the base 7, two side cleats 10 and a rear cleat 11 are fastened byscrews 12 to the base 7 to provide a frame for retaining the end plate2, which is supported on the base with its apertured face up, in properposition. In order to lock the end plate 2 firmly in position, a lockingcam 13 is provided, having an eccentric shaft 14 which is journalledwith a sliding lit into a bore 15 provided in the front of the base 7.The cam 13 is provided with a lever 16 which may be locked into place bymeans of a spring latch 17 which is fastened to the base 7 by screws 18.In its unlocked position, the cam 13 may be readily removed, permittingthe end plate 2 to slide olf the hase 7 toward the front of the jig,thus permitting it to be removed from the jig without lifting it off thebase.

A beam 19 is supported on posts and is held in place by nuts 20 whichare threaded onto studs 21 which pass through beam 19 and are threadedinto posts 8.

On the beam 19 two superimposed members are supported, the lower ofthese members being generally designated by the reference numeral 22,and the upperV of these members being generally designated by thereference numeral 23. As will be explained in detail, eachof thesesuperimposed members provide a series of apertures in alignment witheach other and with the apertures in the end plate supported on the base7.

The lower member is made up of a plurality of flat elements 24 whichextend horizontally from the rear to the front of the assembly jig. Theflat elements 24v rarg 3 each fastened to separate horizontal shafts 25which are journalled in the beam 19, as may be best seen in Figs. 5 and7. As may be seen in these` gures, shafts 25 eX- tend beyond beam 19 atboth ends. At theforward end, each shaft 25 `is provided with a slot 26(Fig. 7) for receiving a flat element 24 which is held in place by a pin427 (Fig. 5). At the opposite end, the shafts 25 are provided with gears28 which mesh with one another as may be best seen in Figs. 5 and 6.Gears 28 are protected by a casing 29 which is fastened to the beam 19by screws 30 (see Figs. 5 and 6). Each of the shafts 25 are providedwith a separate lubrication nipple 31.

A lever 32 is connected to one of the shafts 25 as can be best seen inFigs. 5 and 6. Rotation of lever 32 from the horizontal to the verticalposition (indicated in dotted lines in Figs. 4 and 6) causes the shafts25, through the agency of gears 2S, to rotate in synchronization throughan angle of 90. Lever 32 may be locked in the hori- Zontal position bymeans of a spring latch 33 which is fastened to post 8 by means ofscrews 34.

When the lever 32 is in the horizontal position, the flat elements 24lie in the horizontal plane. A plan view of the elements 24 in thehorizontal position may be seen in Figs 5 and 8, while a front elevationof the elements 24 in the horizontal position may be seen in Fig. 3.When the lever 32 is moved to the vertical position, the at elements 24are rotated to a vertical plane. A plan view of the elements 24 in thevertical position may be seen in Fig. 7, while Fig. 4 shows in dottedlines a side elevation of one of the elements 24 in this verticalposition.

As may be best seen in Fig. 8, each of the elements 24 are ofapproximately the same width as that occupied by two adjacent rows ofrods and are each provided with a series of notches 35 along theirlength on both sides. These notches are so arranged that in thehorizontal position of the elements 24, a series of apertures areprovided in alignment with the apertures 3 in the end plate supported onthe base 7 (see Fig. 5). Rods 1 are retained in the apertures providedby elements 24 at a point intermediate their length and held in thismanner inproper alignment during assembly operations. The manner inwhich the rods 1 are supported by the elements 24 during assembly isbest seen in Figs. 3, 5 and 8.

When assembling a unit such as that illustrated in the drawings, inwhich the rods in adjacent rows are staggered with respect to oneanother, the notches 35 in adjacent elements are arranged in staggeredrelation such that the unnotched portions 36 of one element 24 serve toretain the rods in rows adjacent to that element in their respectivenotches as is best illustrated in Figs. 5 and 8. ln the embodimentillustrated, the unnotched portions 36 project somewhat into theopposite notches so that the elements 24 intermesh with one another whenin the horizontal position. The two center elements 24 are provided withsemi-circular notches 35a to provide an aperture for receiving thecenter post 4. To retain the rods in the outermost rows in theirrespective notches, a pair of at elements Si) are attached immovably tothe beam 19, extending therefrom horizontally and lying in the sameplane which elements 24 occupy when in their horizontal position.

The axis of rotation A (see Fig. 8) of each of the elements 24 liesbetween a pair of adjacent rows of rods as best seen in Figs. 7 and 8.Thus, when rotated to the vertical position as shown in Fig. 7, the rodsare released from the notches 35. The elements 24 in this positionextend freely between the parallel rows of rods, permitting theassembled unit to be removed from the front of the jig by sliding itforward.

The upper apertured member, designated generally by the referencenumeral 23 is supported from two horizontal bars 37 which are fastenedon top of beam 19 by means of studs 21 and nuts 20. On one of the bars37, the apertured plate38 is hinged. Plate 38 is provided at one endwith a ange 39 which has a longitudinal bore 40 for receiving hingeshaft 40a which also passes through a pair of blocks 41, fastened ateither side of plate 38 to bar 37 by screws 42. Hinged in this manner,the plate 38 may be swung back from its closed position as shown inFigs. 3, 4, 5 and 6 to an open position as shown in Figs. 7 and 8. Plate38 is provided with apertures 43 which, as best illustrated in Fig. 5,are in alignment with the apertures provided by elements 24 and with theaperture 3 in the end plate resting on the base of the assembly jig.

The vibrator unit, generally designated by the reference numeral 9, onwhich the assembly jig rests need not be described in detail since unitsof this type are well known and are commercially available. Theparticular unit shown operates on electric power and is controlled by anon-off switch 44, and is provided with a control knob 45 for controllingthe intensity of vibration. Preferably, means (not shown) are providedfor holding the base of the assembly jig firmly to the vibratorplatform.

In operation, the rst step is to place one of the end plates of the unitto be assembled on the base 7 with its apertured face up, the end platebeing locked in place by means of the locking cam 13. Elements 24 arerotated to the horizontal plane, and the hinged apertured plate 38 isbrought into its closed position as illustrated in Fig. 3 of thedrawing. When this is done, the apertures 43 in the plate 38, theapertures provided by the notched elements 24 and the apertures 3 in theend plate are all in alignment 'with one another.

The rods 1 are then dropped by gravity through the apertures 43 andnotches 35 which together align the rod approximately with the apertures3 in the base plate. At the left in Fig. 3, a rod is shown falling intoplace after having been inserted through the apertured plate 38 and thenotched element 24. Because of the tolerances in the manufacture of therods themselves and in the spacing of the apertures in the end plates,apertures 43 and notches 35 are slightly oversized and 'accordingly therods do not align themselves perfectly with their apertures in the endplate in every case when dropped through apertures 43 and notches 35 inthis manner. On reaching the bottom of its fall a rod will often strikethe surface of the end plate without registering with its aperture. Tocause registration of these rods which come to rest on the surface ofthe end plate vibrator 9 is employed, throughmeans of which vibration isirnparted to the entire assembly jig causing the rods resting on thesurface of the end plate near their respective apertures to quicklyregister with and drop into their proper apertures.

Fig. 3 shows a unit in place on the assembly jig which has beenpartially assembled in this manner. After being dropped in place it mayIbe seen that the assembled rods are held in alignment by means of thenotched elements 24. It will be noted that the rods in place terminatebelow the apertured plate 38.

In the particular unit shown, the rods 1 are held loosely in theirrespective apertures in the end plates, while the centerpost 4 is firmlyanchored in sockets provided in either of the end plates so as tomaintain the end plates in fixed relation. Accordingly, during assembly,the center post is preferably rst dropped into position and anchored inplace with a suitable cement.

After all the rods have been installed in the manner described above,the hinged plate 38 is then swung back exposing the tops of theupstanding rods held in approximate alignment in notches 35 provided bythe elements 24. The second end plate is then placed into position withits apertures in approximate alignment with this assemblage'ofupstanding rods. By means of the vibrator 9, the entire assembly is thensubmitted to vibration which causes the rods 1 and the center post 4 toregister substantially simultaneously with their proper apertures.

In Fig. 3, the second end plate4 is shown in dotted lines in theposition it occupies just after assembly.

The socket for the center post 4 is provided with a coat of a suitablecementing compound before this last assembly step so that when assemblyis thus completed the two end plates will be securely anchored at eitherend of the, center post.

The assembly of the unit being thus complete, the unit is`ready to beremoved from the jig. This is accomplished by moving the lever 32 fromits horizontal to a vertical position causing the elements 24 to rotatethrough a 90" angle froml av horizontal to a vertical plane, therebydisengaging the rods from the'notches 35. In this position, which isbest illustrated in Fig. 7, the elements 24 are completely disengagedfrom the rods and extend between the parallel rows of rods asillustrated in this figure. After unlocking and removing the cam lock13, the assembled unit may then slide freely out of the front of theassembly jig.

It is of course understood that many variation-s are possible within thescope of the invention to adapt the unit specifically illustrated totake care of assembling units `of varying construction. For example, ifthe rods in the unit to be assembled are arranged in rows which are notstaggered, the arrangement shown in Fig. 9 may be employed. In thisarrangement, elements 24a similar to elements 24, but of slightlydifferent construction are employed. The elements 24a are also arrangedto be rotated in synchronization from a horizontal to a vertical planeand are also provided with notches 35a along their length on both sides.However, because the rods in adjacent rows are directly opposite oneanother, additional means are necessary to retain the rods in theirrespective notches. This is provided in the arrangement illustrated inFig. 9 by stiff rods 46 extending from the beam 19a in the same plane aselements 24a in their horizontal position. As in the case of theembodiment previously described, when the elements 24a are rotated tothe vertical position, the rods become disengaged from the slots 35a,the elements 24a freely extending between the parallel rows of rods,permitting the assembled unit to slide forwardly from the assembly jig.

It will be clear that many other variations are possible within thespirit of the invention and that the scope of the invention is notlimited to the specic embodiments illustrated, but should be determinedby reference to the appended claims.

I claim:

l. An assembly jig for assembling a unit comprised of a plurality ofrods supported between a pair of end plates provided with apertures toreceive them which comprises a base for supporting one of said endplates during assembly operations, said base being provided withpositioning means operative to position said one end plate thereon, apair of superimposed members positioned above said base, each providingapertures in alignment with eachother and with the apertures in the saidone end plate as supported and positioned on said base, the lower ofsaid members being made up of a plurality of horizontally extendingelements arranged in side-by-side relationship and each being separatelymounted for rotation about a horizontal axis, said elements being soconstructed and arranged that when rotated to one position they togetherprovide a series of apertures in which said rods are retainedtemporarily during assembly of said unit, and when rotated to a secondposition release said rods to permit the assembled unit to be removedfrom the jig, the upper member being spaced above the ends of said rodswhen in assembled position, and serving in cooperation with said lowermember to align said rods with the apertures in said end plate as therods are dropped into position.

2. An assembly jig for assembling a unit comprised of a plurality ofparallel rows of rods supported between a pair 4of end plates providedwith apertures to receive them which'comprises a base for supporting oneof said end plates during assembly operations, a pair of superimposedmembers positioned above said base, each providing apertures inalignment with each other and with the apertures in the end platesIsupported on said base, the lower of said members being so positionedas to engage said rods at a point intermediate their length to hold themin the proper alignment during assembly, and being made up of aplurality of horizontally extending at elements having a widthapproximating the width occupied by two adjacent rows of rods in theassembled unit, each element being provided with notches along itslength on either side thereof adapted to receive said rods, saidelements being arranged in side-by-side parallel relationship, eachbeing separately mounted at one end for rotation about a horizontal axisto permit the notched faces thereof to be moved to and from horizontaland vertical planes, the axis of rotation `of each element extendingbetween adjacent parallel rows of assembled rods whereby the rods inthese adjacent -rows are retained in the notches in the faces of saidelements when these notched faces are in the horizontal plane, andwhereby said rods are released from said notches, permitting theassembled unit to be removed from the jig, when these notched faces arerotated to the vertical plane, the upper member being spaced above theends of said rods when in assembled position, and serving in cooperationwith said lower member t-o align said rods with the apertures in saidend plate as the rods are dropped into position.

3. An assembly jig for assembling a unit comprised of a plurality ofparallel rows of rods supported between a pair of end plates providedwith apertures to receive them which comprises a base for supporting oneof said end plates during assembly operations, said base being providedwith positioning means operative to position said one end plate thereon,said base also being provided with clamping means operative to clampsaid one end plate during the assembling operation, an upright framesupported from said base, a pair of superimposed members positionedabove said base and supported on said frame, each providing apertures inalignment with each other and with the apertures in the said one endplate as supported and positioned `on said base, said lower member beingso positioned as to engage said rods at a point intermediate theirlength to hold them in proper alignment during assembly, said lowermember being made up of a plurality of ilat elements provided withnotched faces extending horizontally from said frame and arranged inside-by-side parallel relationship, each being separately mounted at oneend on horizontal shafts supported by said frame for rotation about ahorizontal axis to permit the notched faces thereof to be moved to andfrom horizontal and vertical planes, the axis of rotation of eachelement extending between adjacent parallel rows of assembled rodswhereby the rods in these adjacent rows are retained in the notches inthe faces of said elements when these notched faces are in thehorizontal plane, and whereby said rods are released from said notches,permitting the unit to be removed from the jig, when these notched facesare rotated to the vertical plane, the upper member being movablyfastened to said frame in a position above the ends of said rods when inassembled position, and serving in cooperation with said lower member toalign said rods with the apertures in said end plate as the rods aredropped into position, and being movable to permit the second end plateto be installed while said rods are held in place by said lower member,and vibrating means disposed beneath said base for subjecting the jig tovibration to assist in the assembly yof said unit.

4. A method for assembling a unit comprised of a plurality of lrodssupported between a pair of end plates provided with apertures toreceive them which comprises the steps of supporting one of said endplates on `a'hase withits apertured face up,rdropping each rod bygravity into `a position approximately in 4alignment with its properaperture, subjecting said base to `vibration while retaining said rodsin said position of approximate alignment thereby causing said rods toregister with and drop into said apertures, and thereafter placing thesecond end platein a position on top-of the-assembly of upstanding rodsheld in approximate alignment with the apertures in said second endplate, and vibrating theentire assembly thereby causing said rods toregister 4substantially simultaneously with the apertures in said secondend plate.

`References Cited yinthe le `ofthis patent UNITED STATES PATENTSCoffelder May .11, Herr June 19, Kiessling May '9, Marvin Aug. .25,Gunter Dec. v14, Schafer Aug. 5, Klinkert July 14,

FOREIGN PATENTS France gMar. 9,

